Automotive exhaust component and process of manufacture

ABSTRACT

A catalytic converter for an internal combustion engine exhaust system is manufactured by a multi-step swaging process carried out in a transfer press. The press has a plurality of swaging stations that include swaging die sets that provide a graduated series of swaging steps. The process is operated continuously, with one of the swaging steps being carried out in each station during each press stroke.

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/867,925, filed Jun. 15, 2004 now U.S. Pat. No. 7,323,145,which is a continuation-in-part of U.S. patent application Ser. No.10/389,868, filed Mar. 18, 2003 and issued Jan. 30, 2007 as U.S. Pat.No. 7,169,365, and further claims the benefit of provisional U.S. PatentApplication Ser. No. 60/367,419, filed Mar. 26, 2002. Each ofapplication Ser. Nos. 10/867,925, 10/389,868 and 60/367,419 isincorporated herein in its entirety by reference thereto.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of automotive exhaust components;and more particularly, to a muffler, catalytic converter or the like,that is formed and housed within a seamless enclosure.

2. Description of the Prior Art

It is widely recognized that the exhaust emissions of internalcombustion engines constitute a major source of air pollution throughoutthe world. The combustion process in these engines inevitably results inthe production of certain substances that pass into the exhaust streamand are detrimental to the health and well being of humans and otheranimal and plant species. The emissions of concern include particulates(soot) along with gases such as CO, SO₂, NO_(x), and imperfectly burnedhydrocarbons (HC). These substances are produced in the combustionprocess, along with the CO₂ and H₂O that are the products of thecomplete oxidation of the hydrocarbons comprised in fuel.

The combination of market forces and governmental environmentalregulations has spurred research and development of ways to mitigate oreliminate the production of the harmful constituents in engine exhaust.Automakers and suppliers have been challenged to control and reducevehicle tailpipe emissions by the U.S. Clean Air Act of 1965 andsubsequent legislation in the U.S. and other countries. In response tothis legislation, virtually every system in the engine has beenimproved. As a result, modern engines more efficiently convert thelatent chemical energy in fuels to useful mechanical work, so that theiremissions are markedly reduced.

To date significant efforts have been directed toward the four-strokeOtto engine in passenger automobiles, owing to consumer preferences andgovernment action. Despite progress in emission reduction for theseautomobile engines, increasingly stringent limits are being imposed.Emission regulations have also extended to other on-road vehicles, suchas busses, and trucks, many of which employ diesel engines; to off-roadvehicles; and to non-propulsion engines, many of which are two-stroke.

Much of the reduction in noxious emissions is attributable to use ofcatalytic converters through which exhaust gas streams are directed. Thepassage of the exhaust across a surface comprising a suitable catalystpromotes further chemical reaction that removes a substantial fractionof the noxious CO, NO_(x), and HC substances, converting them insteadinto more benign substances such as CO₂, O₂, N₂, and H₂O. Moreover, useof catalytic converters in combination with computer-driven, adaptivecontrol of timing and fuel-air mixture gives an engine designersignificant flexibility when optimizing engine-operating parameters toachieve reduced emissions.

Notwithstanding the market pull coming from the significant advantagesrealized by interposition of catalytic converters in the exhaust stream,there remain substantial impediments to their manufacture. It would bedesirable if converters could be manufactured using reliable, efficientand inexpensive construction processes; and maintained durability andfunctionality over a prolonged service life. However, conventionalconverters fail to afford these desirable characteristics.

Converter constructions must produce a gas-tight enclosure so thatexhaust enters solely at an inlet port and exists exclusively through anoutlet port. Failure to achieve a hermetic sealing deleteriously allowsleakage of exhaust gas, circumventing the beneficial effect of thecatalyst and producing unacceptable noise. In some cases, leakage ofexhaust containing combustible gases can lead to engine backfiring anddamage to other portions of the engine system. Leakage can also exposevehicle occupants to unhealthy or dangerous levels of CO and otheremissions. In addition, leaks have been known to trigger catastrophicvehicle fires.

Understandably, automobile manufacturers are impelled by several factorsto minimize or eliminate these catalytic converter failures. Thereputation of a manufacturer as a supplier of a high-quality product isdegraded by reported failures. In addition, both market forces andcurrent U.S. environmental regulations compel an auto manufacturer towarranty the integrity and efficacy of all aspects of an auto'spollution control system. More specifically, the regulations requirethat the system function to maintain the auto's emissions withinestablished standards for an extended period of time and mileage. Anyfailures expose the manufacturer to costly warranty repairs and to theire of an inconvenienced consumer.

Heretofore, the metal housings used for catalytic converters have mostlyfallen into three broad categories of construction: a “pancake” or“clamshell” form, a wrapped form, and a multipiece form, each of whichencloses a catalytic substrate bearing catalytically active material.

Typically, the “pancake” or “clamshell” form comprises stamped upper andlower shells, which are substantially identical to each other, and whichhave mating, peripheral, side flanges that are welded together to lie ina plane containing the longitudinal axis of the housing. They are shapedto form an internal chamber in which the catalytic substrate is mountedby “L-shaped” or other known brackets or pre-formed features providedintegrally in the housing component shells.

The wrapped-form housing is made with material that initially issheet-like and formed so as to generally encircle the catalyticsubstrate. This form is also known as a “tourniquet wrap,” reflectingits construction. The edges of the housing must be joined at a weldedseam that runs essentially the full axial length of the converter. Theinlet and outlet ports in this construction may either be formed as partof the wrapping operation or, more commonly, may comprise separatecomponents welded to the ends of the housing subsequent to the formationof the sheet material.

Several multipiece housing constructions are known. One form disclosedby U.S. Pat. No. 5,118,476 comprises a tubular middle section in whichthe catalytic substrate is placed and end bushings attached to each endof the middle section. U.S. Pat. No. 6,001,314 discloses a two-piecehousing. Each of the pieces is shaped by deep drawing to provide an openend and a conical outer end tapered to an opening appointed forconnection to associated exhaust system pipes. The two pieces are weldedtogether with the catalytic substrate contained within.

Each of these multi-piece constructions must be sealed by welding,either to close a seam in a sheet-like material or to affix appropriateend caps. The welding is needed both to provide the required hermeticsealing of the housing and to secure the catalytic substrate. However,each of these welds is a likely failure mode. Moreover, the OBD2(on-board diagnostics) standard mandated by the U.S. EnvironmentalProtection Agency for passenger vehicles after 1996 imposes a furtherneed for hermetic integrity in the engine exhaust system. This standardmandates measurement of O₂ content before and after the catalyticconverter as a required input for the computerized engine controlsystem. Even a pinhole leak in the system between the sensorscompromises the accuracy of the comparison in O₂ levels which is usedfor a mass balance determination. The emissions control system fails,negating the ability of the engine control system to adaptively optimizetiming and fuel/air mixture to minimize emissions. Such failure of theemissions control system must be corrected under warrantee by thevehicle manufacturer at considerable expense and inconvenience to theconsumer.

The environment of a catalytic converter is harsh for a multiplicity ofreasons, each of which can potentially cause penetrating corrosion andultimate failure of the converter housing. For example, a converter usedin an on-road vehicle, especially in cold climates, is exposedexternally to a spray of road salt and internally to acidic exhaustgases. It is well known in the art that chemical and stress effectscombine to make weldments especially likely loci of corrosive attack.Accordingly, a catalytic converter housing that could be formedefficiently and economically into a single piece without welding haslong been sought in the automotive art. Such a one-piece catalyticconverter housing would overcome serious shortcomings involving thereliability of extant multi-piece and welded housing forms.

The only known technique for producing single-piece housings isspinning. In this process, a catalytic element is placed within a tubeand the combined workpieces are rapidly spun about the tube'scylindrical axis while suitable tools are brought into contact with thetube at each of its ends. Sufficient deformation is thus accomplished toform tubular ports of reduced diameter at each end of the tube.Depending on the required reduction, the spinning may be carried outeither cold or hot. While the spinning approach does produce asingle-piece housing, it also carries substantial drawbacks. Theproduction forming is expensive and energy-intensive to conduct.Moreover, it results in formation of circumferential ridges on both theinside and outside surfaces of the housing in the deformed region. Theseridges are both unattractive and present significant disruption of thegas flow inside the muffler, causing turbulence and undesirable backpressure that reduce the engine power available for a given cylinderdisplacement. The magnitude of diameter reduction achievable by spinningis limited. In addition, substantial work hardening is produced in themetal in the reduced section. As a result, the ductility of the tube inthe reduced section, including the port tubulation, is too low to allowthe converter to be attached to adjoining exhaust sections by ordinaryclamps. Welded or flanged joints must be used instead. The need forwelding joints is particularly inconvenient for aftermarket and repairuse.

The spinning process is further limited by the size and shape of productthat it can produce. Very long shapes are unwieldy to secure and spin atthe required rate in available lathes and similar machine tools.Moreover devices produced by spinning must be rotationally symmetricabout a cylindrical axis, or the resulting imbalance makes it impossibleto spin the device and accomplish the needed forming of the desiredshape. In many cases the circuitous path available for the exhaustsystem would make it highly desirable to have non-symmetric componentsavailable, such as a catalytic converter in which the inlet and outletports need not be coaxially aligned, but angulated or offset relative toone another. Such configurations cannot be formed by known spinningmethods. Furthermore, areas of the housing formed by spinning arework-hardened to an extent that renders subsequent bending and likeoperations virtually impossible.

As a result of these deficiencies, spinning is not widely used in themanufacture of exhaust components, notwithstanding the eagerness of themarket for a viable single-piece, seamless device which spinning mightbe thought capable of producing.

SUMMARY OF THE INVENTION

In an aspect of the present invention there is provided a catalyticconverter for an internal combustion engine exhaust system having asingle-piece, seamless metallic housing, and a process for constructingthe converter. The catalytic converter comprises: (i) a tubulated gasinlet port in the housing through which exhaust gas is introduced; (ii)a tubulated gas outlet port in the housing through which the exhaust gasis discharged; (iii) a tubulated intermediate section of the housinghaving an inlet end and an outlet end; (iv) an inlet transition sectionconnecting the inlet port and the inlet end of said intermediatesection; (v) an outlet transition section connecting the outlet end ofthe intermediate section and the outlet port; and (vi) one or morecatalytic elements contained within the intermediate section and throughwhich the exhaust gas passes when flowing between the gas inlet port andthe gas outlet port. The interior surfaces of the inlet and outlettransition sections and the gas inlet and outlet ports are smooth andsubstantially free from ridges thereon. The inlet and outlet ports andthe inlet and outlet transition sections are formed by swaging the endsof a seamless tube used to form the housing. As used herein, the term“seamless metallic tube” is understood to mean a generally cylindricalmetallic tube produced, e.g. by extrusion, or a tube formed by shaping along, relatively narrow sheet into a tube like structure by bringingopposite, generally parallel edges of the sheet into abutment andjoining the edges by welding.

Exhaust gas produced by operation of the engine passes into theconverter and through the catalytic element. Noxious substances in theexhaust, including CO, NO_(x), and incompletely combusted hydrocarbonsare converted to more benign substances through the action of thecatalytic element, which preferably comprises a frangible ceramichoneycomb structure having a plurality of internal passages coated withone or more catalytically active substances.

Advantageously, the one-piece, seamless converter construction of theinvention is economical to produce and eliminates welding of housingcomponents that are highly prone to failure. More specifically, theone-piece, seamless construction of the converter housing reduces thesize and number converter parts (as compared with known practicalconstructions) while, at the same time, increasing the converter'seffectiveness and improving its construction and manufacture. Theconverter is inherently economical to produce and can bemass-manufactured in the large volumes required to supply originalequipment converters directly to manufacturers of automobiles and trucksfor factory installation in exhaust systems. Furthermore, theimprovement of the housing affords additional advantages includingbetter vehicle fuel efficiency and better manufacturing economics.

The elimination of any welding of seams or end caps afforded by theone-piece construction of the present catalytic converter greatlyenhances its reliability during service. Welds are notoriouslyvulnerable as loci of corrosive attack due both to chemical and stresseffects. In operation, catalytic converters in typical on-road vehicleapplications are exposed externally to road salt and other corrosivesubstances and internally to acidic exhaust gases. The absence ofweldments in the present catalytic converter removes a prime source offailures during the service life of the device.

The manufacture of the catalytic converter of the invention comprisesuse of swaging processes to form the tubulated ends of the catalyticconverter. The central section of the housing, being generally larger ininner dimension than the ends, envelops and holds the catalytic elementin position. Swaging is used in the practice of this invention generallyto reduce the ends of the housing to a tube diameter appointed forconnection of the converter to the adjoining components of the engineexhaust system.

Compared to other known methods used to form ends, swaging often affordsa number of advantages. The reduction in diameter can be carried out ina sequence of steps using a plurality of dies. In some instances, amulti-step swaging process is desirable, because the needed deformationis too great to be attained practically using a single press operation.By swaging sequentially, the required press force at each stage isgreatly reduced. As a result, the swaging process is highly adaptable,providing a designer with great flexibility in tailoring a housing tofit into an available space and in optimizing the dynamics of gas flowthrough the device. The tubulated ends and transition sections aresmooth and substantially free of circumferential ridges on either theinside or outside surfaces. The external appearance of the device isenhanced. The smoothness of the inside surface and the absence of ridgesthereon minimizes generation of turbulence that impedes the flow ofexhaust gas through the converter and causes excessive backpressure.Swaging ordinarily maintains a level of ductility sufficient to allowthe converter to be connected to the rest of the exhaust system byclamped, welded, or flanged joints.

A further benefit offered by some embodiments of the present processover spinning is the ability to form more intricate structures,including those having features such as extended length and bends orother non-symmetrical configuration. Since the present end-formingprocess does not entail rapid rotation of the workpiece, neitherrotational balance nor the size of available lathes or similar machinetools is a consideration. End forming can thus produce converters havinginlet and outlet ports and transitional sections which can be round orhave a variety of other shapes, such as that of ovals, and especially“flat ovals”, needed to accommodate vehicle clearance or other size andspace requirements. A converter could also be formed with bends in anyof its sections. Designs can also be formed wherein the catalyticelement is an oval cylinder instead of a right circular cylinder.

In one aspect of the invention the catalytic element comprises afrangible ceramic honeycomb structure having a plurality of passagesextending therethrough. The surfaces of the passages are substantiallycovered with a finely dispersed, catalytically active substance. Thisconstruction makes effective use of the catalytic substance, whichgenerally comprises one or more of the expensive platinum-group noblemetals including Pd, Pt, and Rh. The ceramic honeycomb is preferablyencircled with a mat of an intumescent material which acts toresiliently and insulatively secure it within the inside diameter of theintermediate section. The intumescence of the mat material creates areliable and gas-tight seal that protects the ceramic during itsconstruction and in-service life. In addition, the intumescent materialforces the exhaust gas stream to pass through the passages of thehoneycomb, maximizing catalytic efficacy.

An embodiment of the present process involves the use of a transferpress, which may be a linear or rotary transfer press, to end-formmultiple workpieces in each press stroke. The transfer press provides anordered sequence of swaging stations sequentially enumerated from “1” to“n,” “n” having a value of at least 2. Each of said swaging stationscomprises a die set, the die sets being adapted to a carry out insequence a plurality of “n” graduated swaging steps that collectivelyswage each of the preforms at said first end to form said gas inlet portand said inlet transition section and at said second end to form saidgas outlet port and said outlet transition section. The processcomprises: (a) inserting at least one catalytic element into each of thepreforms; (b) an initiation operation wherein one of the preforms withthe at least one catalytic element is disposed in each of the swagingstations to prepare the press to be activated to simultaneously carryout the swaging steps in all of the swaging stations; and (c) thereafterrepetitively operating the press such that: during the stroke of eachpress cycle is accomplished the step of: (i) actuating said transferpress to simultaneously carry out the swaging steps in all of theswaging stations; and during each transfer interval are accomplished thesteps of: (ii) providing one of said seamless metallic tube preformshaving said at least one catalytic element inserted therein; (iii)situating the preform in the first swaging station; (iv) removing afinished converter from said final swaging station; and (v) transferringa partially swaged preform from each of swaging stations “1” to “n−1” tothe succeeding swaging station.

In yet another aspect, there is provided a process for producing acatalytic converter using a transfer press as before, and wherein theprocess comprises: (i) providing a seamless metallic tube preformadapted to be formed into the housing, the preform having a first endand a second end, and at least one catalytic element inserted therein;(ii) transferring the preform sequentially through each of the “n”swaging stations; and (iii) activating said press while said preform isin each of said “n” swaging stations to carry out a corresponding one ofsaid swaging steps, whereby said catalytic converter is produced.Optionally the press comprises an indexing mechanism adapted to carryout the transferring. The indexing mechanism may be further operative toreceive the preform into the first swaging station and thereafter totransfer it sequentially through the remaining swaging stations and toremove the catalytic converter from the transfer press after the swagingstep of the final station is accomplished.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood and further advantages willbecome apparent when reference is had to the following detaileddescription of the preferred embodiments of the invention and theaccompanying drawings, wherein like reference numerals denote similarelements throughout the several views and in which:

FIG. 1 is a perspective view of a catalytic converter in accordance withthe invention;

FIG. 2 is a longitudinal, cross-sectional view along the axial mid-planeof the catalytic converter depicted by FIG. 1;

FIG. 3 is a longitudinal, cross-sectional view along the axial mid-planeof a catalytic converter in accordance with another aspect of theinvention;

FIG. 4 is an axial cross-sectional view taken in the intermediatesection of the converter depicted by FIG. 3;

FIG. 5 is a fragmentary longitudinal cross-sectional view taken alongthe axial mid-plane of a catalytic converter having plural catalystelements in accordance with another aspect of the invention;

FIG. 6 is a fragmentary longitudinal cross-sectional view taken alongthe axial mid-plane of a catalytic converter having plural catalystelements of different diameters and disposed in different intermediatesubsections in accordance with another aspect of the invention;

FIG. 7A is a fragmentary longitudinal cross-sectional view taken alongthe axial mid-plane showing an intermediate stage in one process forfabricating the housing of the converter depicted by FIG. 6;

FIG. 7B is a fragmentary longitudinal cross-sectional view taken alongthe axial mid-plane showing an intermediate stage in an alternateprocess for fabricating the housing of the converter depicted by FIG. 6;

FIG. 8A is a fragmentary longitudinal cross-sectional view taken alongthe axial mid-plane showing an intermediate stage in one process forfabricating the housing of the converter depicted by FIG. 6;

FIG. 8B is a fragmentary longitudinal cross-sectional view taken alongthe axial mid-plane showing an intermediate stage in an alternateprocess for fabricating the housing of the converter depicted by FIG. 6,the view of FIG. 8B taken subsequent to the stage seen in FIG. 8A.

FIG. 9A is a perspective view, partially cut away, of a tube preformengaged by gripping dies during production of one implementation of thepresent process for producing a catalytic converter;

FIG. 9B is a horizontal longitudinal cross-sectional view of the tubepreform engaged by gripping dies also shown in FIG. 9A, thecross-section taken at level IX-IX of FIG. 9A;

FIG. 10 is a perspective view, partially cut away, illustrating ahorizontal transfer press being used to form elements;

FIG. 11 is a cross-sectional plan view depicting in greater detailcertain of the elements of the horizontal transfer press shown in FIG.10; and

FIGS. 12A-12O provide a schematic representation of the stages of acontinuous production process for catalytic converters, implementedusing a horizontal transfer press depicted by FIGS. 10-11.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed to a catalytic converter, a processfor producing the converter, and an internal combustion engine systemusing the converter. As used herein and in the subjoined claims, theterm “catalytic converter” is understood to mean a catalytic converter,muffler, pre-catalytic converter, or the like, adapted to beincorporated in the exhaust system of an internal combustion engine.Generally stated, the catalytic converter is housed in a single-piece,seamless metallic housing preferably made of a corrosion-resistant metalalloy such as a stainless steel alloy. The housing has tubulated gasinlet and outlet ports through which exhaust gas is introduced anddischarged, respectively. The converter alternatively comprises a singlecatalytic element or a plurality of cascaded catalyst elements containedwithin a tubulated intermediate section of the housing. During itspassage through the converter, exhaust gas is caused to flow over thesurface of the one or more catalyst elements. A catalytically activematerial present on each catalyst element promotes chemical reactionsthat purify the gas stream. This is accomplished by converting certainchemical species therein to other species which are generally considerednot harmful to life or the environment, or which present a significantlyreduced danger.

Referring now to FIGS. 1 and 2 there is shown generally at 10 acatalytic converter comprising one aspect of the invention. Thecatalytic converter 10 has a one-piece, seamless metal housing composedof a corrosion-resistant metal, preferably stainless steel. Theembodiment depicted by FIG. 1 is generally cylindrical, having a roundcross-section at each point along its axial length. However, in otherembodiments the housing may have a non-circular cross-section, such as aflat oval. Housing 12 is generally tubular in shape, and is providedwith tubulated gas inlet port 14 having inlet orifice 16 and tubulatedgas outlet port 18 having outlet orifice 20. Converter 10 is appointedfor use in the exhaust system of an internal combustion engine (notshown). Inlet port 14 is connected to tubulated intermediate section 22of housing 12 by inlet transition section 24. Intermediate section 22 isconnected to outlet port 18 through outlet transition section 26.Exhaust gas produced during operation of the internal combustion engineenters the converter through inlet orifice 16 in inlet port 14. Theexhaust gas then passes successively through inlet transition section24, intermediate section 22, and outlet transition section 26, beforebeing discharged through outlet orifice 20 of outlet port 18. Inlet andoutlet ports 14, 18 of converter 10, though of reduced diameter owing tothe manufacturing process described hereinafter, are not work hardened.As a result, the ports, 14, 18 of converter 10 can be readily connectedto other components of the exhaust system by welded, clamped, andflanged joints produced by suitable means known in the engine art.

The arrangement of the components inside the catalytic converter 10 ofFIG. 1 is best seen in the cross-sectional view of FIG. 2. Converter 10further comprises catalytic element 28. In an aspect of the inventioncatalytic element 28 comprises a generally cylindrical, frangible,heat-resistant ceramic honeycomb substrate 30 having a large number ofpassages 32 therethrough, each of the passages 32 running generallyparallel to the cylindrical axes of both substrate 30 and intermediatesection 22. Passages 32 are generally arranged in a honeycomb pattern ora similar array. Passages 32 extend completely through substrate 30,thereby allowing the passage of gas from one end 34 of element 28 to theother end 36 thereof. In an aspect of the invention substrate 30 iscomposed of cordierite. Other ceramic materials having adequatestrength, thermal shock resistance, heat resistance, and chemicalcompatibility both with the exhaust gas stream and catalyst materialapplied thereto may also be used. The interior surfaces of passages 32are substantially covered with a substance catalytically active toinduce the chemical reaction of substances present in engine exhaust forthe purification thereof. In some aspects of the invention, catalyticelement 28 may comprise a plurality of ceramic or other substratesarranged sequentially or in parallel, e.g. to achieve better gas flow,to provide more than one type of catalyst, or to facilitate manufactureof a longer converter. Sequentially disposed substrates may be insubstantially abutting relationship or may be separated by a free spacewhich may be desired for optimizing gas flow.

One skilled in the art will also appreciate that while the embodimentshown in FIGS. 1 and 2 is cylindrically symmetric, the invention alsocontemplates aspects in which bends, angulations, and othernon-symmetric features may be present. The intermediate section may beoval or “pancake” shaped and have a catalyst element of mating shapetherein. The inlet and outlet ends, as well as the intermediate section,may be coaxially directed, as shown in FIGS. 1-2. Alternatively, thehousing may be structured in such a way that the ends may be directedalong parallel but offset directions, or at a relative angle.

In addition, the inlet and outlet ends may be extended to serve asportions of the engine exhaust system. While this extension entailsadditional forming steps, the corresponding reduction in the number ofparts in the total engine exhaust system is advantageous both forsimplifying assembly and for eliminating otherwise required joints thatare also prone to corrosion failure.

The present catalytic converter employs any of a variety of knowncatalytically active substances. Many of these substances contain noblemetals such as Pt, Pd, and Rh. As a result of the needs to (i) use thesehigh cost materials as efficiently as possible and (ii) maximize thecatalytic surface's effective area, the catalyst material is generallyprovided in a finely divided form coated on, and adhered to, a catalyticsubstrate. Suitable catalyst materials include three-way catalystsappointed to convert nitrous oxides, carbon monoxide, and hydrocarbonsto nitrogen, water, and carbon dioxide. Means for selecting a suitablecatalyst material and for ascertaining the specific activity and theeffective surface area of a catalytic material are well known in thecatalyst art. The converter may also comprise an oxidation catalyst andmeans (not shown) for supplying secondary air to intermediate section 22so as to promote conversion of carbon monoxide and hydrocarbons to waterand carbon dioxide. Other forms of catalyst substrate, includingmetallic catalyst support systems, may also be used in the practice ofthe present invention.

Ceramic substrate 30 is preferably supported and held securely insealing contact within intermediate section 22 by a generally encirclingmat 38. The mat is preferably resilient, insulative, and shock absorbentand may be composed of a gas impervious, vermiculite based material,available in the open market. Such a material is intumescent, that is,it expands substantially upon heating. Typically a mat having an initialthickness of approximately ¼″ is used. During assembly of converter 10,mat 38 is wrapped to substantially encircle the ceramic substrate 30 andcover at least a portion of its longitudinal or axial length.Preferably, a short portion of the cylindrical periphery of the ceramicsubstrate 30 at each of its ends 34, 36 is left uncovered by mat, asdepicted by FIG. 2. Preferably, the axial length uncovered at each endranges from about half to three times the thickness of the mat. Thisholdback ensures that portions of the mat do not break off and block anyof the passages through honeycomb structure 30. The wrapped mat 38 iscompressed radially to a thickness approximately half of its initialthickness prior to insertion of the combined substrate 30 and mat 38into the inner diameter of intermediate section 22 to secure thepositioning of the combined assembly within the converter housing 12.

One form of mat suitable for the practice of the invention comprises aflexible intumescent sheet, which may be used for mounting automotivecatalytic converter monoliths. The sheet comprises an unexpandedvermiculite produced by subjecting vermiculite ore containinginterlamellar cations to a potassium nitrate solution for a timeinterval sufficient to ion exchange interlamellar cations within the orewith potassium ions; an inorganic fibrous material; and a binder. Thesheet material may be provided with, or temporarily laminated to, abacking sheet of kraft paper, plastic film, non-woven synthetic fiberweb, or the like. Another suitable form of intumescent sealing mat 38 isavailable on the market under the trade name of “3M INTERAM MAT.”Suitable intumescent sealing mat is also sold commercially by Unifrax astype “XPE.”

Advantageously the intumescence of mat 38 ensures the secure mounting ofcatalytic substrate 30 within the converter housing. In addition, theintumescent mat 38 seals the gap between the outside cylindrical surfaceof catalytic substrate 30 and the inside cylindrical surface ofintermediate section 22. This “sealing action” forces substantially allthe gas flowing into the converter 10 through inlet port 16 to passthrough internal passages 32 in substrate 30 before exiting throughoutlet port 18. Efficacy of the catalytic material coating the surfaceof internal passages 32 is thereby enhanced, since exhaust gas ismaximally exposed to the catalytically active material. The resiliencyof mat 38 serves to cushion and protect frangible substrate 30 duringthe initial fabrication of converter 10. Moreover, mat 38 retains thisresiliency even after repeated thermal cycling. The constituents ofconverter 10 experience differential thermal expansion and contractionduring each cycle of heatup, operation, and cool-down of the enginewherein exhaust passes through converter 10. By virtue of maintainingits resiliency, mat 38 is able to protect substrate 30 from damage dueto this pattern of differential expansion, while still maintaining anadequate degree of sealing during the entirety of each operating cycle.

While the aspect of the invention depicted by FIG. 1 comprises acatalytic converter employing a catalyst dispersed and supported on aceramic substrate, other forms of catalyst and substrate may also beused in the practice of the invention. For example, a catalyst may bedispersed on a metallic substrate, which may take the form of corrugatedmetal foil that is coiled upon itself to form a generally cylindricalstructure having a plurality of passages longitudinally extendingtherethrough. Since metals are substantially less frangible and tougherthan known ceramic catalyst substrates, a metal catalytic support ofthis form may allow elimination of intumescent material 38 in theconstruction of converter 10.

A variety of metallic alloys are suitable for the housing of theinvention. Alloy selection is made on the basis of cost and the level ofperformance required with respect to temperature capability, durability,and corrosion resistance needed. For automotive use, ferritic stainlesssteels are commonly used, including various 400-series alloys. Mostcommonly 409SS and SAE51409 alloys are employed. For small engines,including non-propulsion applications, and other instances where costconsiderations are dominant, carbon steels are frequently used. Fordemanding applications wherein especially long life and high corrosionresistance are desired, such as marine engines, austenitic and300-series stainless steel alloys such as 304SS are generally employed.

The catalytic converter of the invention may be manufactured in a widerange of sizes to accommodate the requirements of different engines,which may range from small engines of a few horsepower or less, such asmight be used in lawn mowers, snow blowers, weed trimmers, and similaroff-road, non-propulsion applications, to large diesel engines used intrucks. Many present automotive applications employ ceramic substratescommercially available in standard diameters of 2.5 and 4 inches.Automotive converters are typically about 9 to 20 inches in totallength. Small, non-propulsion engines may employ substrates as small as1-inch diameter or even less and may be only a few inches long. Theminimum length of the substrate is generally determined by the flowvelocity and the amount of time the exhaust gas must be at the catalyticsurface to achieve a chemical reaction that sufficiently reduces theconcentration of pollutants. The total length of the converter is thendetermined both by the length of the active catalyst and the requiredshaping of the transition sections and the inlet and outlet ports. Oftenthe inlet and outlet ports of a converter are approximately half thediameter of the substrate to reduce exhaust flow impedance. The taperingof the inlet transition and outlet transition sections may range fromvery gradual to very abrupt. For automotive applications the transitionsections are often chosen with a straight taper of 10-15° forsimplicity. However, curved transitions provided in some implementationsof the present converter are generally advantageous for betteraerodynamics. In one aspect of the invention, the intermediate sectionis cylindrical and the length of the inlet and outlet transitionsections is chosen so that each length ranges from about 30% to 100% ofthe diameter of the intermediate section.

The catalytic converter shown in FIGS. 1-2 and described hereinabove isof the so-called under-floor type normally disposed under the floor ofan automotive vehicle for reasons of available space. However, it willbe understood by one skilled in the art that the principle of thepresent invention may be applied to catalytic converters of manydifferent types, including those types appointed to be mounted proximatethe exhaust manifold of an internal combustion engine. These types aresometimes denoted as pre-cat catalytic converters if mounted withinabout thirty-six inches of the manifold or as pre-light catalyticconverters if mounted within about eight inches of the manifold.Additionally, it will be appreciated that the principle of the presentinvention may be applied to the manufacture of catalytic converters fora variety of internal combustion engines other than those of anautomotive vehicle, and converters that are integrated with mufflers,resonators, or other similar components in the exhaust system.

In accordance with an aspect of the invention, the inlet and outlettransition sections and the inlet and outlet ports of the catalyticconverter are formed by swaging. In the aspect of the invention depictedin FIGS. 1-2, the converter housing 12 is formed from a cylindricalmetallic tube, the diameter of which is uniform through its length. Theends of the tube are swaged to form the transition sections 24, 26 andthe ports 14, 18 with mat 38 and substrate 30 being located inintermediate section 22. As depicted by FIG. 2, the inside diameter ofintermediate section 22 through substantially its entire length isd_(t). A swaging operation forms transition section 24 and inlet port14, tapering the tube smoothly to a diameter of d_(i) in the inlet portregion, so that inlet port 14 may be attached to the preceding componentof the exhaust system. A swaging operation is also used to form outlettransition section 26 and outlet port 18. The diameter d_(o) of outletport 18 may be the same as diameter d_(i) of inlet port 14.Alternatively, different diameters may be selected to accommodate therequirements of the exhaust system.

In FIGS. 3 and 4 there is shown an aspect of the invention comprising avariation of the form of the housing 12 depicted by FIGS. 1 and 2. Inthis aspect, a further forming operation, which may include swaging, isoptionally applied to intermediate section 22 of housing 12 to formtherein a plurality of rib-like indentations 50, which are axiallyelongated along intermediate section 22. Preferably indentations 50extend along a substantial portion of intermediate section but do notextend to inlet and outlet transition sections 24, 26. Thecross-sectional view of FIG. 4, taken at lines A-A shown by FIG. 3,depicts an aspect in which three such indentations are present.Preferably indentations 50 extend radially inward to a depth of at mosthalf the thickness of intumescent mat 38. They act to further supportand constrain mat 38 and substrate 30 from axial movement and to assuresealing of the mat/substrate assembly within the walls of housing 12.Indentations 50 should not be so deep as to cause fracture of substrate30.

FIG. 3 also depicts optional circumferentially extending indentations 52at the junction between inlet transition section 24 and intermediatesection 22 and at the junction between intermediate section 22 andoutlet transition section 26. These indentations 52 serve to support andconstrain substrate 30 from moving axially. If present, theseindentations are preferably of a depth less than or about equal to thethickness of the mat. This indentation in some cases also advantageouslyimproves the uniformity of gas flow across presented at the face area ofsubstrate 30. In other embodiments a screen, baffle, or similarstructure may also be used to protect the inlet and outlet of theceramic substrate from the intrusion of foreign matter and to improvegas flow.

The swaging used to form each of the ends of converter housing 12 iscarried out by mechanically forcing a suitably configured die over eachend of the tube, the force being applied in a generally axial directionand the die being designed to cause flow of the metal and thereby reducethe tube's diameter while maintaining its circularity. Preferably, theswaging is carried out in a plurality of swaging steps using a pluralityof dies to form each end of the converter housing 12. A suitablesequence of dies may further be used to achieve a desired profile in thetransition section. The profile may be as simple as a cone, butalternatively comprises a more complicated pattern having a combinationof curvatures in which there is no discontinuity in the slope of theinside surface of the converter in its axial direction. In someembodiments of the invention both ends of the housing are swagedsimultaneously by applying oppositely directed compressive forces todies on each end using hydraulically driven rams.

The flexibility in choosing the profile of the transition sections ofthe present converter is highly advantageous. The profile ischaracterized, in part, by the curvature at each point along the lengthof the transition sections and the overall rapidity with which thesections taper. A converter designer must satisfy several constraints.The overall length of the converter may be limited to a maximum lengthby available space. The required gas flow rate, allowable impedance togas flow, and required extent of exposure of the exhaust to activecatalyst, along with available forms of substrate and the geometry ofthe passages therethrough, generally constrain the area and lengthrequired for the catalytic element. In addition, properly designedtransition sections advantageously maintain a generally laminar flow ofexhaust gas and minimize the generation of unwanted turbulence therein.This turbulence undesirably increases the impedance of the catalyticconverter and results in excessive backpressure. The absence of theabove-mentioned discontinuity in slope in the transition sections,together with suitable transition profiles with gradually tapereddiameters, minimizes this turbulence.

A further benefit of swaging over other forming techniques, such asspinning, is its ability in most cases to produce reduced sections whilemaintaining smoothness of both the interior and exterior surfaces of theconverter. When properly carried out, significant reductions in diametercan be made without producing internal and external circumferentialridges that are typically produced by spinning. If present, such ridgeson the interior surface of an exhaust component are a further source ofundesirable turbulence, as previously discussed. In addition, theswaging technique ordinarily results in an exterior surface that issmooth and aesthetically appealing, minimizing its vulnerability topitting, corrosion, or like attack, and rendering it easily finishableby plating or other coating operations. Preferably, the swagingtechnique also produces an inner surface that is substantially smoothand free of significant ridges. If present, such ridges on the interiorsurface of an exhaust component are a further source of undesirableturbulence, as previously discussed.

A further disadvantage of techniques such as spinning is the amount ofwork hardening that results in the reduced section. This work hardeningis highly detrimental in that it leaves the inlet and outlet ports witha ductility level that is insufficient to allow the ports to be reliablyand hermetically attached to other exhaust components by clamping.Instead, joints have to be made using welds or flanges, which are moreexpensive and difficult to implement, especially with after-marketinstallations.

The present catalytic converter may be manufactured in otherconfigurations. For example, the converter may incorporate a pluralityof cascaded catalytic elements. FIG. 5 depicts such an embodiment 11including two catalyst elements 28, 28′ in a generally cylindricalconverter. Each of the elements is of substantially similar size and isencircled by an intumescent mat 38. The elements are laterally spaced bya distance s₁. Preferably, s₁ is at least 10% of diameter d_(t). Exhaustgas enters through inlet port 14 and transits elements 28 and 28′,sequentially entering end 34 of element 28 and exiting at end 36,transiting the space between the elements, and then entering end 34′ ofelement 28′ and exiting at end 36′, and finally exiting the converterthrough outlet port 18. In some embodiments, the elements 28, 28′include substantially the same catalytically active material, which maybe a coating applied to a ceramic honeycomb substrate such ascordierite. However, the elements may also incorporate differentcatalytic substances, which may be optimized to catalytically promotedifferent reactions. For example, one catalyst may be of a type used toconvert NO_(x) to N₂+O₂, while another catalyst may be of a type used tocompletely combust unburned HC. Other combinations, and configurationsemploying more than two elements, are also understood to be within thescope of the invention.

In addition, the various catalytic elements may be of differentdiameters. One such configuration 70 employing three catalytic elementsis seen in FIG. 6. In this embodiment, the intermediate section of thecatalytic converter includes subsections 72, 74, and 76, in whichcatalytic elements 78, 82, and 84, respectively, are disposed. Thesubsections are joined by transitions 73, 75. The embodiment shown alsoincludes intumescent mats 80 encircling and securing each of thecatalytic elements in their respective subsections. The subsectionssequentially decrease in diameter from transition inlet end 90 to outletend 91. In other embodiments (not shown), one or more of the transitionsections 73, 75 may include a bend, so that ends 90 and 91 may benon-coaxial or offset from one another. Such shapes are advantageouslyemployed in some vehicle applications, wherein the exhaust system mustfollow a circuitous route due to the lack of any available straight pathfrom the engine to the desired terminus of the exhaust system.

The ability to employ plural catalysts and to configure them onsubstrates of different diameters provides significant designflexibility in providing maximum catalytic efficacy. The differentmaterials can be selected to promote different reactions that addressthe multiple undesirable constituents in a typical exhaust stream. Bychanging the geometrical configuration of the overall converter and theindividual catalytically active elements, the flow pattern and resultingexhaust gas residence time can also be beneficially optimized. Thegeometric flexibility is also beneficial in vehicle designs in which theavailable space for locating the converter and other exhaust systemcomponents is often limited and circuitously disposed in the vehicleundercarriage.

Multi-stage converter configurations, such as that depicted by FIG. 6,may be manufactured using a number of manufacturing techniques, whichmay be carried out in a variety of orders. The housing with itsintermediate subsections of the requisite diameters can be formed beforeor after the different catalyst elements are inserted.

In one implementation usable to make the housing depicted by FIG. 6,there is provided a preform having the approximate diameter of thelargest subsection 72. As shown generally at 70′ in FIG. 7A, swaging isthen used to reduce the diameter of a portion of the preform long enoughto accommodate sections 74 and 76, thereby creating temporary subsection74′, with the concomitant formation of transition 73 of the ultimatelydesired shape. A subsequent swaging operation (not shown) is applied toa portion of temporary subsection 74′ to form the ultimately desiredsubsections 74 and 76, with transition 75.

Alternatively, as seen generally at 70″ in FIG. 7B, a preform with theapproximate diameter of the largest subsection 72 is again provided.Subsection 76 is first formed, creating temporary subsection 72″ andtransition 75″. A subsequent swaging is then carried out to formsubsection 74 and reshape temporary transition 75″ into transition 75having the desired shape, as shown in FIG. 6.

Either of the formations shown in FIGS. 7A-7B may be carried out beforeor after insertion of the catalytic elements. Other sequences may alsobe employed. For example, the formation of subsections and the insertionof the associated catalytic elements can be carried out in alternation.Such a sequence is also preferably employed if the transitions includebends. It is also possible to create the transitions between subsectionsby other forming methods such as spinning. However, the aforementionedswaging is preferred, since it ordinarily produces an inner surface thatis smooth and substantially ridge-free, whereby flow disruption isminimized. Also, a housing that is not cylindrically symmetric is fareasier and more efficient to form using swaging than spin forming orother similar processes.

In an aspect of the process of the invention the forming operation iscarried out semicontinuously. Seamless tubes having substantially thediameters desired for the intermediate section (or the largest of itssubsections) are supplied in long lengths. From these tubes are cutpreforms adapted to be formed into the catalytic converter housing.Ceramic substrates are provided having the desired diameter and length.Each substrate is wrapped with an intumescent mat to form the catalyticelement. The mat is compressed and the combined assembly inserted intothe free end of the supply tube. The supply tube is then grippedcircumferentially and its free end is swaged to form the inlet port andinlet transition section. Subsequently, the supply tube is cut to removea portion thereof having a requisite preselected length, therebydefining the preform. The preform is then re-gripped and the other endswaged to form the outlet port and outlet transition section. Most ofthe steps of this process are easily automated to provide a high levelof manufacturing efficiency and process control, thereby minimizingproduction costs.

In another aspect of the process of the invention, preforms are cut tolength from a seamless tube having substantially the diameter desiredfor the intermediate section of the converter. A ceramic substratehaving the requisite length is wrapped with an intumescent mat to formthe catalytic element and inserted approximately in the middle of eachpreform. The preform, with its substrate, is then placed in a hydraulicram assembly having swaging dies coaxially aligned and adapted to beforced compressively over each of the preform's ends, therebysimultaneously swaging each end. A plurality of dies are sequenced intoa hydraulic ram and used stepwise to accomplish the desired reduction tothe final inlet and outlet port diameters and to form the inlet andoutlet transition sections. Alternatively, a plurality of rams are used,with the preform being indexed between rams, which are appointed with adesired sequence of dies to progressively swage the ends in a pluralityof graduated swaging stages.

One process by which the catalytic converter partially depicted by FIG.6 may be manufactured is further elucidated by reference to FIGS. 8A-B.There is provided a tube preform having approximately the diameter ofthe largest subsection 72 of the cascaded arrangement of intermediatesection 70. Catalytic substrate 78 encircled by intumescent mat 80 isfirst inserted into section 72. Thereafter, an end of the preform isend-formed by forcibly inserting the preform into swaging die 92 adaptedto reduce the diameter of the preform to create temporary subsection 74′and transition 73. Then the workpiece is removed from die 92 andcatalytic substrate 82 encircled by intumescent mat 80 is disposed intemporary subsection 74′ at a preselected location. The preform, nowbearing substrates 78 and 82, is again end-formed using swaging die 94,which reduces the diameter of part of the preform to the sizepreselected for section 76 and creates transition section 75. In stillanother step (not shown), substrate 84 and encircling intumescent mat 80are inserted in the preform. Both ends of the preform are swaged toprovide inlet and outlet ports. It will be recognized that while theembodiment of the invention depicted by FIGS. 6-8 employs three cascadedcatalytic elements, embodiments with other numbers of catalyticelements, ranging from two to four or more elements are also possibleand are to be understood as being within the scope of the presentinvention. As noted above, the housing, including the intermediatesection and subsections graduated in diameter may be formed prior toinsertion of the catalytic elements into the respective subsections, orthe forming and insertion operations for each subsection may beaccomplished in alternation, as set forth above. Implementations inwhich the individual forming and insertion operations are alternatelyaccomplished also permit bends or offsets to be formed between thesubsections. They also permit formation in which the sizes of thevarious subsections do not increase or decrease in strict sequence.However, configurations having sequentially decreasing diameters of thesubsections, such as that depicted in FIG. 6, are especially preferredand simpler to form.

It will be understood that swaging operations are ordinarily carried outwith part of a tube preform secured by grips so that sufficientaxially-directed force may be applied to form at least one of the tubeends into the desired configuration, although methods in which the inletand outlet ends are formed simultaneously may rely on the oppositelydirected axial swaging forces to eliminate the gripping or reduce theamount of gripping force needed.

In some implementations of the present process, the gripping operationis accomplished by gripping dies that substantially encircle the tubeand provide radially directed force to reduce the diameter of an innersection of the preform. One such operation is shown generally at 94 byFIGS. 9A-B. Two gripping dies 96 are disposed to surround preform 98.The dies 96 are urged together by force radially directed at F, as seenin FIG. 9B. Dies 96 are adapted to create reduced diameter section 100joined to the remainder of tube 98 by transition sections 102. In theembodiment shown, the reduction is carried out with catalytic elementinserted in the section to be reduced. The element may comprise ceramicsubstrate 104 with encircling intumescent mat 105, as depicted, or anyother form of catalytic element. Although two complementary dies areshown, other embodiments may employ three or more complementary dieswhich collectively surround tube 98 and, when forced radially, cause asubstantially cylindrical reduction of the tube diameter. The force usedto compress dies 96 is ordinarily provided hydraulically, but otherknown sources of mechanical force may also be used.

The use of gripping dies that simultaneously reduce a tube diameterbeneficially improves the efficiency of a tube fabrication process byeliminating a step in many known forming processes. In particular,gripping operations capable of opposing the substantial axial forcesrequired are frequently required for successful end forming. Heretofore,a separate step for reducing the diameter of an intermediate portion ofthe tube has been required. However, the use of dies that accomplishboth the required gripping and reduction eliminates a process step.

In still another aspect, there is provided a process for continuouslyproducing the present catalytic converters by multi-step swaging carriedout in a transfer press. An implementation of such a process using ahorizontal transfer press is depicted generally at 150 by FIGS. 10-11.The press includes opposing heads 151, 152 that can be driven togetherin a linear stroke in the directions indicated generally by arrows 168,170. Then the heads withdrawn in the opposite directions. Most commonly,such a press is hydraulically operated, but other pneumatic ormechanical drives known in the art may also be used.

The implementation of FIG. 10 provides four swaging stations defined byswaging die sets (154 a, 154 b), (156 a, 156 b), (158 a, 158 b) and (160a, 160 b) and corresponding lower grips 154 c, 156 c, 158 c, and 160 cand mating upper grips (not shown). A cylindrical preform 162 may beswaged to provide the shape of a finished converter 172 by carrying outin sequence a swaging step in each of the four swaging stations. As bestseen in FIG. 11, the die sets provide a graduated sequence ofdeformations that reduce the initial diameter of the cylindrical preformto the smaller diameter of the finished inlet and outlet ports andprovide a tapered transition section at both ends. In otherimplementations, the number of swaging stations is as small as two.During each swaging step, the preform is gripped and supported by thepertinent upper and lower grips.

As seen in FIG. 10, swaging dies 154 a, 156 a, 158 a, and 160 a form afirst bank 153 secured on first head 151; and swaging dies 154 b, 156 b,158 b, and 160 b form a second bank 161 secured on second head 152. Insome implementations, a single swaging step is carried out in one of theswaging stations during each actuation of the press. An initiallycylindrical preform 162 is provided with at least one catalytic element164 inserted therein. Preferably, catalytic element 164 is securedwithin preform 162 using an encircling intumescent mat, as describedabove.

The press of FIGS. 10-11 may be operated in various sequences. Aftereach press cycle, indexing mechanism 176 accomplishes one or more ofreceiving new cylindrical preforms 162, removing finished converters 172from the transfer press, and indexing partially swaged preformssequentially through the plural swaging stations. In the implementationof FIGS. 10-11, indexing mechanism includes two sets of four forks thatact as transfer cradles. For clarity, only the set proximate head 154 isshown; a corresponding set proximate head 152 is not depicted. Thetransfer cradles engage and grasp an exterior round surface of thepreforms undergoing swaging. Indexing mechanism 176 is moved in agenerally rectangular pattern indicated by arrows 174 in concert withthe press cycles to advance the preforms in the appointed sequence.Alternatively, indexing mechanism 176 may have other structural featuresto carry out its function of engaging and grasping the preforms andmoving them in and out of the press and between swaging stations. Forexample, forks or prongs may engage either the inner or outer surface ofthe preform and may be inserted part-way into the bore of the preformsat one or both ends. The indexing mechanism may also incorporatemagnets.

To begin the process, a preform 162 is moved into the first swagingstation and the first swaging step is carried out by actuating thepress. The partially swaged preform is then sequenced through each ofthe subsequent swaging stations to permit the remaining swaging steps tobe accomplished in subsequent press cycles.

The process depicted by FIG. 10 may further incorporate a formingoperation of the type illustrated by FIGS. 9A-B carried out in one ormore of the swaging stations. In particular, one or more of lower grips154 c, 156 c, 158 c, and 160 c and the corresponding upper grips areconfigured to surround the preform so as to carry out a reduction indiameter of at least part of the intermediate section of the preform asit is processed through the pertinent swaging station. Other grippingarrangements may also be used.

In other implementations, the press and process of FIGS. 10-11 is usedto form multi-stage converters having a plurality of cascaded catalyticelements, such that the converter depicted in FIG. 5 or FIG. 6 isproduced.

Preferably, a continuous process is implemented using the apparatus ofFIGS. 10-11 by simultaneously carrying out swaging steps in each of theswaging stations during each press cycle. More specifically, the processflow is depicted by FIGS. 12A-O. An initiation operation begins at FIG.12A, which shows cylindrical preform 162 with inserted catalytic element164. At FIG. 12B, preform 162 is advanced into a ready position, withanother preform waiting. Indexing mechanism 176 engages preform 162 andmoves it into position in the first swaging station (FIG. 12C). Indexmechanism 176 is retracted and the press is actuated to carry out astroke (FIG. 12D) and then retracted (FIG. 12E) during the transferinterval. Indexing mechanism 176 engages the now partially swaged firstpreform and the next cylindrical preform in waiting (FIG. 12F) and movesthem into the second and first swaging stations, respectively (FIG.12G). A third new preform is made ready (FIG. 12H). The press is againactuated, producing two partially swaged preforms (FIG. 12I). These twoare indexed to the next stations; the third preform is loaded and afourth preform is made ready (FIG. 12J). In the next stroke, threepreforms are swaged (FIG. 12K). As the process continues, the swagingstations are fully populated (FIG. 12L). The next press stroke completesformation of the first converter in the final swaging station (FIG.12M). Indexing mechanism 176 then extracts the first finished converter(FIG. 12N), completing the initiation operation.

Thereafter, the process is continued indefinitely. During the strokeportion of each subsequent press cycle, all the swaging stations arepopulated (FIG. 12O) and a swaging step is accomplished in each; duringeach subsequent transfer interval, a finished converter is extractedfrom station 4, partially swaged converters are indexed from stations 1to 3 to stations 2 to 4, respectively, and a new preform is introducedinto station 1.

It will be understood that the implementation of FIG. 10 can readily bemodified to include different numbers of swaging stations to accommodatethe manufacture of housing shapes best formed with differentcorresponding numbers of swaging steps. It will further be understoodthat the FIG. 10 implementation can be modified in various ways. Forexample, the press might apply force in a vertical direction instead ofthe horizontal direction shown, or the various swaging stations might bedispersed vertically or at an inclined angle instead of horizontally.However, the disposition in FIG. 10 may benefit from the use of gravityto assist the feeding of preforms and the removal of finishedconverters. Other implementations employ a rotary transfer press, inwhich plural swaging stations are disposed around the circumference of acylinder and the indexing mechanism provides generally rotationaltransfer of preforms from station to station, instead of a lineartransfer, as in FIG. 10.

The following example is presented to provide a more completeunderstanding of the invention. The specific techniques, conditions,materials, proportions and reported data set forth to illustrate theprinciples and practice of the invention are exemplary and should not beconstrued as limiting the scope of the invention.

Example 1 Preparation and Testing of a Catalytic Converter

A catalytic converter of a type commonly used for emissions reductionfrom an automobile engine was formed using a catalytic elementcomprising a conventional platinum-group noble metal type of catalystsupported on the walls of multiple passages extending through acordierite ceramic honeycomb structure. The honeycomb structure wasabout 3.6 inches in diameter and 3 inches long. The housing for theconverter was formed from a seamless tube of 409 stainless steel alloyhaving an outside diameter of about four inches and 0.049-inch walls.The honeycomb structure was wrapped with an intumescent mat compressedto about 0.12 inches thickness, and the combined mat and ceramic werethen inserted into the center part of the generally tubular converterhousing. The ends of the housing were then end-formed to provide aninlet port section and an outlet port section, each of which having adiameter of two inches and a length of two inches. Tapered transitionsections about two inches long joined the inlet and outlet sections tothe central section.

The converter was subjected to standard tests known in the automotiveindustry and conformed to procedures set forth in 40 CFR 85.2116. Thefollowing tests were conducted.

The expansion of the intumescent mat material was tested by a dial-gagetechnique. The mat was heated to a maximum temperature of 825° C. andits expansion was measured and found to exhibit a maximum of about120-130% relative to its initial thickness. This value is well withinthe usual range known in the art to result in satisfactory sealing andpositioning of a ceramic substrate in a catalytic converter housing.

The cold push-out resistance of the ceramic substrate was measured by astandard mechanical pressing technique. The experiment was carried outby gripping the converter housing and exerting mechanical force throughan arbor pressing axially on the substrate. It was found that a force ofabout 60-80 pounds was required to initiate shear of the intumescent matand cause displacement of substrate. The observed force was well withinstandards recognized in the art, in which movement at less than about 30pounds indicates an inadequately supported and sealed substrate, whilemovement at over about 200 pounds is indicative of excessive engagementof the substrate by the intumescent mat that is likely to result inchipping or brittle failure of the substrate during converter use.

The catalytic efficiency of the converter was measured by a sweep testusing gas chromatographic analysis of the conversion efficiency forknown CO, HC, and NO_(x) pollutants to benign substances. Minimalbackpressure was observed, confirming the adequacy of flow through theconverter, including the catalytic substrate. Satisfactory catalyticefficiency performance was observed, indicating the suitability of theconverter for use in an automotive application that achieves compliancewith applicable emissions standards.

The results of the foregoing tests establish that a one-piece, seamlessconverter satisfactorily demonstrates performance sufficient to meetrequirements for emissions mitigation in an automotive application.

Having thus described the invention in rather full detail, it will beunderstood that such detail need not be strictly adhered to but thatvarious changes and modifications may suggest themselves to one skilledin the art, all falling within the scope of the present invention asdefined by the subjoined claims.

1. A process for producing catalytic converters for an internalcombustion engine exhaust system, the converter having interior andexterior surfaces, using a transfer press capable of being repetitivelyoperated in press cycles comprising a stroke and a transfer interval,each said catalytic converter comprising: a. a single-piece, seamlessmetallic housing formed from a preform having a first end and a secondend; b. a tubulated gas inlet port in said housing through which exhaustgas is introduced; c. a tubulated gas outlet port in said housingthrough which said exhaust gas is discharged; d. a tubulatedintermediate section of said housing connecting said gas inlet port andsaid gas outlet port; e. an inlet transition section connecting saidinlet port and said inlet end of said intermediate section; f. an outlettransition section connecting said outlet end of said intermediatesection and said outlet port; and g. at least one catalytic elementcontained within said intermediate section and through which saidexhaust gas passes when flowing between said gas inlet port and said gasoutlet port; the interior surfaces of said inlet and outlet transitionsections and said gas inlet and outlet ports having been swaged andbeing substantially free from ridges thereon; and said transfer presscomprising an ordered sequence of swaging stations sequentiallyenumerated from “1” to n, having a value of at least 2, each of saidswaging stations comprising a die set, and said die sets being adaptedto a carry out in sequence a plurality of “n” graduated swaging stepsthat collectively swage each of said preforms at said first end to formsaid gas inlet port and said inlet transition section and at said secondend to form said gas outlet port and said outlet transition section suchthat there is created in said perform a reduced diameter section, andwherein said process comprises: inserting at least one catalytic elementinto each of said preforms; an initiation operation wherein one of saidpreforms with said at least one catalytic element is disposed in each ofsaid swaging stations to prepare said press to be activated tosimultaneously carry out said swaging steps in all of said swagingstations, and thereafter repetitively operating said press in said presscycles such that, during each said stroke is accomplished the step of:i. actuating said transfer press to simultaneously carry out saidswaging steps in all of said swaging stations, and during each saidtransfer interval are accomplished the steps of: ii. providing one ofsaid seamless metallic tube preforms having said at least one catalyticelement inserted therein; iii. situating said preform in said firstswaging station; iv. removing a finished converter from said finalswaging station; and v. transferring a partially swaged preform fromeach of said stations “1” to “n−1” to the succeeding swaging station. 2.A process as recited by claim 1, wherein said transfer press is a rotarytransfer press in which said swaging stations are arranged circularly.3. A process as recited by claim 1, wherein said transfer press is alinear transfer press in which said swaging stations are arrangedlinearly.
 4. A process as recited by claim 3, wherein said transferpress is a horizontal transfer press.
 5. A process as recited by claim1, further comprising an indexing mechanism used to accomplish at leastone of said situating, removing, and transferring steps.
 6. A process asrecited by claim 5, wherein said indexing mechanism is used toaccomplish said transferring step.
 7. A process as recited by claim 6,wherein said indexing mechanism comprises a plurality of magnets thatengage and grasp said partially swaged preforms during saidtransferring.
 8. A process as recited by claim 6, wherein said indexingmechanism comprises a plurality of forks that engage and grasp saidpartially swaged preforms during said transferring.
 9. A process asrecited by claim 8, wherein said forks engage and grasp an exteriorsurface of said partially swaged preforms during said transferring. 10.A process as recited by claim 8, wherein said forks engage and grasp aninterior surface of said partially swaged preforms during saidtransferring.
 11. A process as recited by claim 5, wherein said indexingmechanism comprises a plurality of prongs, one of said prongs beinginserted into at least one end of said partially swaged preforms duringsaid transferring.
 12. A process as recited by claim 1, wherein eachsaid catalytic element comprises: a. a ceramic substrate having aplurality of passages extending therethrough; and b. a catalytic activematerial present on a substantial portion of the surface of each of saidpassages; and c. an intumescent mat adapted to encircle said ceramicsubstrate and to seal the external surface of said ceramic substrate tothe inner surface of said intermediate section; and said process furthercomprises the step of: encircling each of said ceramic substrate withsaid intumescent mat to form said catalytic element prior to itsinsertion into said tube preform.
 13. A process as recited by claim 1,wherein said catalytic converter comprises a plurality of cascadedcatalytic elements through which said exhaust gas passes sequentiallywhen flowing between said gas inlet port and said outlet port.
 14. Aprocess as recited by claim 13, wherein said intermediate section isswaged said plural swaging steps to form a plurality of subsections andat least one of said catalytic elements is disposed in each of saidsubsections.
 15. A process as recited by claim 1, wherein said swagingproduces a plurality of rib-like indentations axially elongated alongsaid intermediate section.
 16. A process for producing a catalyticconverter for an internal combustion engine exhaust system, theconverter having interior and exterior surfaces, said catalyticconverter comprising: a. a single-piece, seamless metallic housingformed from a preform having a first end and a second end; b. atubulated gas inlet port in said housing through which exhaust gas isintroduced; c. a tubulated gas outlet port in said housing through whichsaid exhaust gas is discharged; d. a tubulated intermediate section ofsaid housing connecting said gas inlet port and said gas outlet port; e.an inlet transition section connecting said inlet port and said inletend of said intermediate section; f. an outlet transition sectionconnecting said outlet end of said intermediate section and said outletport; and g. at least one catalytic element contained within saidintermediate section and through which said exhaust gas passes whenflowing between said gas inlet port and said gas outlet port; theinterior surfaces of said inlet and outlet transition sections and saidgas inlet and outlet ports having been swaged and being substantiallyfree from ridges thereon; and said transfer press comprising an orderedsequence of swaging stations sequentially enumerated from “1” to “n”,“n” having a value of at least 2, each of said swaging stationscomprising a die set, and said die sets being adapted to a carry out insequence a plurality of “n” graduated swaging steps that collectivelyswage each of said preforms at said first end to form said gas inletport and said inlet transition section and at said second end to formsaid gas outlet port and said outlet transition section such that thereis created in said perform a reduced diameter section, and said processcomprises: i. providing a seamless metallic tube preform adapted to beformed into said housing, said preform having a first end and a secondend, and at least one catalytic element inserted therein; ii.transferring said preform sequentially through each of said “n” swagingstations; and iii. activating said press while said preform is in eachof said “n” swaging stations to carry out a corresponding one of saidswaging steps, whereby said catalytic converter is produced.
 17. Aprocess as recited by claim 16, wherein said transfer press furthercomprises an indexing mechanism adapted to carry out said transferring.18. A process as recited by claim 17, wherein said indexing mechanism isfurther operative to receive said preform into said first swagingstation and thereafter to transfer it sequentially through saidremaining swaging stations.
 19. A process as recited by claim 18,wherein said indexing mechanism is further operative to remove saidcatalytic converter from said transfer press after said swaging step insaid final station is accomplished.